Read by scripts/questionnaire.py. Section heading format: ### <Section> | weight <n> | <types or all> | <min risk>.
Question format: - [KO] <question> | <evidence> ([KO] = knockout: scoring 0 or 1 blocks approval).
Types: machining, electronics, chemical, distributor, service. Min risk: low (always asked), medium, high.
Management system | weight 15 | all | low
- [KO] Is the site certified to ISO 9001 (or IATF 16949 / AS9100 / ISO 13485) by an accredited certification body? | Certificate, scope, expiry, accreditation mark
- Are quality objectives set and reviewed by top management? | Objectives, last management review minutes
- Is there an internal audit programme covering all processes, with findings closed? | Programme, last 2 reports
- Is there a named quality contact with authority to stop shipment? | Org chart
Contract review and planning | weight 10 | all | medium
- Are customer drawings, specifications and revision levels reviewed before order acceptance? | Order review records
- Are special characteristics and customer-specific requirements flowed to production? | Router, control plan
- Is capacity checked before accepting orders and delivery dates? | Capacity plan
Sub-tier supplier control | weight 10 | all | medium
- Are sub-tier suppliers selected and evaluated against defined criteria? | Approved supplier list, evaluations
- Are customer requirements (including special processes and approved sources) flowed down on purchase orders? | Sample POs
- Is incoming material verified (inspection or certificates) before use? | Receiving records, CoCs
Process control | weight 20 | machining,electronics,chemical | low
- [KO] Are work instructions and control plans available and current at the point of use? | Station documents vs register
- Is first-piece / set-up approval done and recorded before each run? | First-off records
- Are special processes (heat treatment, plating, welding, soldering, sterilization) validated and monitored? | Validation reports, parameter records
- Is preventive maintenance planned and recorded for critical equipment? | PM plan, records
- Are key characteristics monitored with SPC and reacted to? | Control charts, reaction log
Inspection, test and measurement | weight 15 | machining,electronics,chemical | low
- [KO] Are all gauges and test equipment calibrated and traceable to national standards? | Calibration register, labels
- Is final inspection performed and recorded before shipment? | Final inspection records
- Has MSA (Gage R&R) been done for gauges used on key characteristics? | MSA studies
- Can the site produce the inspection reports or CoCs the customer requires? | Sample report
Nonconforming product and corrective action | weight 15 | all | low
- [KO] Is nonconforming product identified and segregated so it cannot be shipped? | Quarantine area, NCR log
- Are customers notified and concessions obtained before shipping deviating product? | Concession records
- Are root causes analysed (8D, 5 Why) and effectiveness verified? | Sample CAPAs
- Are customer complaints answered within the required time? | Complaint log, response times
Traceability, storage and delivery | weight 10 | all | medium
- Can finished product be traced to material lots and process records? | Trace exercise
- Are storage conditions, shelf life and FIFO controlled? | Storage area, stock records
- Is packaging defined and adequate to protect the product? | Packaging specs
- Is on-time delivery measured and acted on? | OTD KPI
Machining specifics | weight 5 | machining | high
- Are tool life and offsets controlled and recorded? | Tool life records
- Is material certification checked against the specification (grade, heat number)? | Mill certs vs spec
- Are burrs, chips and coolant contamination controlled before packing? | Cleaning instruction
Electronics specifics | weight 5 | electronics | high
- Is ESD control implemented and verified (ANSI/ESD S20.20 or IEC 61340-5-1)? | ESD audits, wrist strap logs
- Are moisture-sensitive devices handled per J-STD-033 (floor life, baking)? | MSL log
- Are workmanship standards (IPC-A-610 class) defined and operators certified? | IPC certificates
- Is counterfeit-part avoidance in place for components (authorized sources)? | Purchasing records
Chemical specifics | weight 5 | chemical | high
- Are batch records complete and reviewed before release? | Batch records
- Is a certificate of analysis issued per batch against the agreed specification? | CoA samples
- Are raw-material shelf life and storage conditions controlled? | Stock records
- Are change notifications (formulation, site, source) sent to customers in advance? | Change notification procedure
Distributor specifics | weight 5 | distributor | low
- [KO] Is product bought only from the original manufacturer or its authorized channel? | Franchise agreements, purchase records
- Is traceability to the original manufacturer's lot maintained and stated on the CoC? | CoC samples
- Is there a counterfeit detection and reporting process (e.g. AS6081 for independent distributors)? | Procedure, reports
Service specifics | weight 20 | service | low
- [KO] Are staff competence requirements defined and records kept? | Competence matrix, certificates
- Are service reports or job records completed and reviewed? | Sample job records
- Is customer property (equipment, data, sites) protected? | Procedure, incident log
8d-problem-solving-report-writer
Write and review 8D problem-solving reports for customer complaints and serious nonconformities (automotive and aerospace practice: Ford Global 8D, VDA, GM, Stellantis formats): D0 emergency response, D1 cross-functional team and champion, D2 problem description with 5W2H and is / is-not and no cause in the statement, D3 interim containment within 24 hours with verification and clean point, D4 verified occurrence and escape (non-detection) root causes plus systemic cause, D5 permanent corrective actions for each cause verified before implementation, D6 implementation, validation with production data and removal of containment, D7 PFMEA, control plan and read-across to similar products, D8 closure and recognition. Checks an 8D discipline by discipline for missing content, human-error root causes, missing escape cause or action, late containment and dates out of order.
acceptance-sampling-plan-selector
Select and evaluate acceptance sampling plans for incoming, in-process and final inspection: ANSI/ASQ Z1.4 / ISO 2859-1 single sampling under normal inspection (code letter from lot size and inspection level I, II, III, S-1 to S-4; sample size, Ac and Re from AQL, following the table's arrows to the correct plan; 100% when n reaches the lot size; AQLs above 10 per 100 units), operating characteristic curves (Pa at any quality, producer's quality level, indifference point, LTPD, AOQ and AOQL, binomial or hypergeometric), plans designed from producer and consumer risk, and c = 0 zero-acceptance plans. Covers AQL choice by defect class, switching rules between normal, tightened and reduced inspection, when sampling is not appropriate, and random sampling.
approved-supplier-list-manager
Manage and audit an approved supplier list (ASL) / external provider register for ISO 9001 8.4.1, IATF 16949 8.4 and AS9100 8.4.1: supplier status (approved, conditional, probation, pending, disqualified), scope of approval by commodity and process, risk class, certification and expiry, re-evaluation intervals by risk, conditions with end dates, single-source contingency, approver and customer-directed sources. Audits the list for expired or expiring certificates, overdue re-evaluations, conditional or probation status past its decision date, high-risk suppliers without the required certification, single-source suppliers without backup and missing approvers, and checks purchase orders for suppliers that are off-list, disqualified or pending, or buying outside the approved scope. Covers ERP blocks, PO requirements, off-list and emergency purchases.
apqp-phase-planner
Plan and track Advanced Product Quality Planning (AIAG APQP 3rd edition, IATF 16949) for a new or changed automotive part: back-schedule the five phases (plan and define, product design, process design, product and process validation, launch and feedback) from the start-of-production date by program complexity, with overlap, PPAP lead and safe-launch period; list the deliverables and gate for each phase (DFMEA, DVP&R, feasibility, process flow, PFMEA, control plans, MSA, Ppk, run at rate, PPAP, safe launch, lessons learned); adjust for build-to-print suppliers; flag compressed timelines and late or untracked deliverables against a status list. Covers gate reviews, red/yellow/green status reporting, run at rate and safe-launch exit criteria.
as9100-gap-analyzer
Run an AS9100D / EN 9100:2018 gap analysis for aviation, space and defence suppliers on the requirements added to ISO 9001: on-time delivery and conformity focus, management representative, ethics and human-factors awareness, operational planning and operational risk management, configuration management, product safety, counterfeit-part prevention, special requirements, critical items and key characteristics, external provider register and flow-down, FOD prevention, tooling and NC program control, special process validation, first article inspection (AS9102), traceability, in-service data and nonconforming product control. Generates and scores a worksheet, grades missing core controls as major, and checks invalid n/a claims. Covers AS9101/AS9104, OASIS, AS9102 FAI forms, counterfeit standards (AS5553, AS6174, AS6081), NADCAP and the planned IA9100 transition.
audit-report-writer
Write internal, supplier and pre-certification audit reports with the content ISO 19011:2018 6.5 expects: audit objectives, scope, criteria with revisions, dates, team and auditees, method and sampling statement, specific strengths, findings table and three-part finding details (requirement, evidence, statement), conclusion on the degree of fulfilment of criteria, diverging opinions, follow-up deadlines and distribution. Builds a Markdown report from a JSON audit record, generates the conclusion from the findings (major / minor / none) and flags reports missing required content or findings without clause or evidence. Covers conclusion wording, closing meetings, response expectations and verifying corrective actions.